![Kawasaki WORKHORSE 250 (2003) [138/322] 4 engine removal installation](/img/pdf.png)
Kawasaki WORKHORSE 250 (2003) [138/322] 4 engine removal installation
![Kawasaki WORKHORSE 250 (2003) [138/322] 4 engine removal installation](/views2/1121215/page138/bg8a.png)
8-4 ENGINE REMOVAL/INSTALLATION
Engine Removal/Installation
Engine Removal
•
Remove:
Engine Oil (drain)
Fuel Tank (see Fuel System chapter)
Rear Fender and Front Fender (see Frame chapter)
Muffler and Exhaust Pipe (see Engine Top End chapter)
Carburetor (see Fuel System chapter)
Reverse Lever and Cable (see Crankshaft/Transmission
chapter)
Spark Plug Cap
Alternator Lead Connector [A]
Crankshaft Sensor Lead Connector [B]
Neutral/Reverse Switch Lead Connectors [C]
•
Remove:
Ground Lead (Engine) [A]
Starter Motor Lead [B]
Engine Breather Hose [C]
•
Loosen the propeller shaft dust cover clamp [A].
•
Remove:
Engine Mounting Bolts and Nuts [A]
Engine Mounting Brackets [B]
•
Free the engine from the propeller shaft and remove the
engine.
Содержание
- Tables 1
- Quick reference guide 3
- All terrain vehicle service manual 5
- Klf 250 bayou 250 workhorse 250 5
- List of abbreviations 6
- Read owner s manual before operating 6
- Emission control information 7
- The phrase remove or render inoperative any device or element of design has been generally interpreted as follows 1 tampering does not include the temporary removal or rendering inoperative of de vices or elements of design in order to perform maintenance 2 tampering could include a maladjustment of vehicle components such that the emission standards are ex ceeded b use of replacement parts or accessories which adversely affect the performance or durability of the motorcycle c addition of components or accessories that result in the vehicle exceeding the stan dards d permanently removing disconnecting or rendering inoperative any component or element of design of the emission control systems 7
- Please do not tamper with noise control system us model only 8
- Foreword 9
- How to use this manual 9
- General information 11
- General information 1 1 11
- Table of contents 11
- 2 general information 12
- Before servicing 12
- Before starting to perform an inspection service or carry out a 12
- Especially note the following 12
- Before servicing 13
- General information 1 3 13
- 4 general information 14
- Before servicing 14
- Two color electrical wire 14
- General information 1 5 15
- Model identification 15
- 6 general information 16
- General specifications 16
- General information 1 7 17
- General specifications 17
- 8 general information 18
- General specifications 18
- General information 1 9 19
- Prefixes for units 19
- Unit conversion table 19
- Units of force 19
- Units of length 19
- Units of mass 19
- Units of power 19
- Units of pressure 19
- Units of speed 19
- Units of torque 19
- Units of volume 19
- Periodic maintenance 21
- Periodic maintenance 2 1 21
- Table of contents 21
- 2 periodic maintenance 22
- Periodic maintenance chart 22
- Basic torque for general fasteners 23
- Periodic maintenance 2 3 23
- Torque and locking agent 23
- 4 periodic maintenance 24
- Torque and locking agent 24
- Periodic maintenance 2 5 25
- Torque and locking agent 25
- 6 periodic maintenance 26
- Specifications 26
- Fuel system 27
- Periodic maintenance 2 7 27
- Periodic maintenance procedures 27
- Throttle lever free play 27
- Throttle lever free play adjustment 27
- Throttle lever free play inspection 27
- 8 periodic maintenance 28
- Periodic maintenance procedures 28
- Warning 28
- Periodic maintenance 2 9 29
- Periodic maintenance procedures 29
- Warning 29
- 10 periodic maintenance 30
- Engine top end 30
- Periodic maintenance procedures 30
- Valve clearance when cold 30
- Warning 30
- Clutch adjustment 31
- Clutches 31
- Periodic maintenance 2 11 31
- Periodic maintenance procedures 31
- Warning 31
- 12 periodic maintenance 32
- Engine lubrication system 32
- Engine oil 32
- Periodic maintenance procedures 32
- Periodic maintenance 2 13 33
- Periodic maintenance procedures 33
- Standard tire 33
- Tire tread depth 33
- Wheels tires 33
- 14 periodic maintenance 34
- Final drive 34
- Final gear case oil 34
- Periodic maintenance procedures 34
- Brakes 35
- Front brake lever free play 35
- Periodic maintenance 2 15 35
- Periodic maintenance procedures 35
- 16 periodic maintenance 36
- Brake pedal free play 36
- Cam lever angle 36
- Periodic maintenance procedures 36
- Rear parking brake lever free play 36
- Warning 36
- Cam lever angle 37
- Periodic maintenance 2 17 37
- Periodic maintenance procedures 37
- Rear parking brake lever and pedal free play adjustment 37
- Warning 37
- 18 periodic maintenance 38
- Electrical system 38
- Periodic maintenance procedures 38
- Spark plug gap 38
- Steering 38
- Brake light switch timing 39
- General lubrication 39
- Periodic maintenance 2 19 39
- Periodic maintenance procedures 39
- 20 periodic maintenance 40
- Periodic maintenance procedures 40
- Bolts and nuts tightening 41
- Periodic maintenance 2 21 41
- Periodic maintenance procedures 41
- Tightness inspection 41
- Fuel system 43
- Fuel system 3 1 43
- Table of contents 43
- Exploded view 45
- Fuel system 3 3 45
- 4 fuel system 46
- Specifications 46
- Fuel system 3 5 47
- Special tools and sealant 47
- 6 fuel system 48
- Throttle case removal disassembly 48
- Throttle lever and cable 48
- Throttle lever free play adjustment 48
- Throttle lever free play inspection 48
- Fuel system 3 7 49
- Throttle lever and cable 49
- Warning 49
- 8 fuel system 50
- Throttle cable lubrication and inspection 50
- Throttle lever and cable 50
- Choke cable lubrication and inspection 51
- Choke lever and cable 51
- Choke lever and cable installation 51
- Choke lever lubrication 51
- Choke lever removal 51
- Fuel system 3 9 51
- Warning 51
- 10 fuel system 52
- Carburetor 52
- Carburetor pilot screw setting 52
- Idle speed 52
- Warning 52
- Carburetor 53
- Float height 53
- Fuel level 53
- Fuel system 3 11 53
- 12 fuel system 54
- Carburetor 54
- Carburetor removal 54
- Fuel system cleanliness inspection 54
- Warning 54
- Carburetor 55
- Carburetor disassembly 55
- Carburetor installation 55
- Fuel system 3 13 55
- Warning 55
- 14 fuel system 56
- Carburetor 56
- Carburetor assembly 56
- Caution 56
- Warning 56
- Carburetor 57
- Carburetor cleaning 57
- Carburetor inspection 57
- Caution 57
- Fuel system 3 15 57
- Warning 57
- 16 fuel system 58
- Carburetor 58
- Air cleaner 59
- Fuel system 3 17 59
- Warning 59
- 18 fuel system 60
- Air cleaner 60
- Air cleaner draining 60
- Air cleaner element cleaning and inspection 60
- Air cleaner housing removal 60
- Fuel system 3 19 61
- Fuel tank 61
- Fuel tank installation 61
- Fuel tank removal 61
- Warning 61
- 20 fuel system 62
- Fuel tank 62
- Fuel tank and fuel tap cleaning 62
- Fuel tap installation 62
- Fuel tap removal 62
- Warning 62
- Fuel level gauge removal 63
- Fuel system 3 21 63
- Fuel tank 63
- Fuel tap inspection 63
- Warning 63
- 22 fuel system 64
- Fuel level gauge check 64
- Fuel level gauge installation 64
- Fuel tank 64
- Warning 64
- Engine top end 65
- Engine top end 4 1 65
- Table of contents 65
- Engine top end 4 3 67
- Exploded view 67
- Engine top end 4 5 69
- Exploded view 69
- 6 engine top end 70
- Specifications 70
- Engine top end 4 7 71
- Specifications 71
- 8 engine top end 72
- Specifications 72
- Engine top end 4 9 73
- Special tools and sealant 73
- 10 engine top end 74
- Special tools and sealant 74
- Camshaft chain tensioner 75
- Engine top end 4 11 75
- 12 engine top end 76
- Camshaft sprocket 76
- Camshaft sprocket 77
- Engine top end 4 13 77
- 14 engine top end 78
- Rocker arms and shafts 78
- Engine top end 4 15 79
- Rocker arm and shaft installation 79
- Rocker arm and shaft removal 79
- Rocker arms and shafts 79
- 16 engine top end 80
- Rocker arm and shaft inspection 80
- Rocker arm inside diameter 80
- Rocker arms and shafts 80
- Rocker shaft diameter 80
- Cam height 81
- Camshaft 81
- Engine top end 4 17 81
- 18 engine top end 82
- Camshaft chain and guides 82
- Camshaft chain guide installation 82
- Camshaft chain guide removal 82
- Camshaft chain guide wear 82
- Camshaft chain installation 82
- Camshaft chain removal 82
- Caution 82
- Cylinder compression usable range 83
- Cylinder head 83
- Engine top end 4 19 83
- 20 engine top end 84
- Compression too high 84
- Cylinder head 84
- Cylinder head removal 84
- Wet compression increase 84
- Wet compression no change 84
- Cylinder head 85
- Cylinder head bolt torque 85
- Engine top end 4 21 85
- 22 engine top end 86
- Cylinder head 86
- Cylinder head cleaning 86
- Cylinder head warp 86
- Engine top end 4 23 87
- Valve clearance adjustment 87
- Valve clearance inspection 87
- Valve removal 87
- Valves guides seats springs oil seals 87
- 24 engine top end 88
- Valves guides seats springs oil seals 88
- Engine top end 4 25 89
- Valve valve guide clearance wobble method 89
- Valves guides seats springs oil seals 89
- 26 engine top end 90
- Valve seat surface outside diameter 90
- Valve seat surface width 90
- Valves guides seats springs oil seals 90
- Engine top end 4 27 91
- Valves guides seats springs oil seals 91
- 28 engine top end 92
- Valves guides seats springs oil seals 92
- Engine top end 4 29 93
- Valves guides seats springs oil seals 93
- Cylinder and piston 95
- Engine top end 4 31 95
- 32 engine top end 96
- Cylinder and piston 96
- Cylinder and piston 97
- Cylinder inside diameter 97
- Engine top end 4 33 97
- Piston diameter 97
- 34 engine top end 98
- Cylinder and piston 98
- Piston cylinder clearance 98
- Piston ring groove clearance 98
- Piston ring groove width 98
- Cylinder and piston 99
- Engine top end 4 35 99
- Piston ring end gap 99
- Piston ring thickness 99
- 36 engine top end 100
- Caution 100
- Exhaust pipe removal 100
- Exhaust system 100
- Muffler removal 100
- Spark arrester cleaning 100
- Engine top end 4 37 101
- Exhaust system 101
- Engine right side 103
- Engine right side 5 1 103
- Table of contents 103
- Engine right side 5 3 105
- Exploded view 105
- 4 engine right side 106
- Specifications 106
- Engine right side 5 5 107
- Special tools and sealant 107
- 6 engine right side 108
- Engine right side 108
- Engine right side disassembly 108
- Engine right side 109
- Engine right side 5 7 109
- 8 engine right side 110
- Engine right side 110
- Engine right side 111
- Engine right side 5 9 111
- 10 engine right side 112
- Clutches 112
- Primary clutch housing inside diameter 112
- Primary clutch shoe groove depth 112
- Clutches 113
- Engine right side 5 11 113
- Friction and steel plate warp 113
- Friction plate thickness 113
- Friction plate warp 113
- Friction plate wear 113
- One way clutch inspection 113
- Steel plate warp 113
- 12 engine right side 114
- Clutch spring free length 114
- Clutch spring free length measurement 114
- Clutches 114
- If any of the springs a is shorter than the service limit it must be replaced 114
- Crankshaft diameter a 115
- Engine right side 5 13 115
- Gear backlash 115
- Primary gear crankshaft wear 115
- Primary gear inside diameter a 115
- Primary reduction 115
- Secondary gear collar diameter b 115
- Secondary gear collar wear 115
- Secondary gear inside diameter a 115
- Recoil starter 117
- Recoil starter 6 1 117
- Table of contents 117
- Exploded view 119
- Recoil starter 6 3 119
- 4 recoil starter 120
- Recoil starter 120
- Warning 120
- Recoil starter 121
- Recoil starter 6 5 121
- Warning 121
- 6 recoil starter 122
- Recoil starter 122
- Recoil starter 123
- Recoil starter 6 7 123
- Warning 123
- Engine lubrication system 125
- Engine lubrication system 7 1 125
- Table of contents 125
- Engine lubrication system 7 3 127
- Exploded view 127
- 4 engine lubrication system 128
- Specifications 128
- Engine lubrication system 7 5 129
- Engine oil flow chart 129
- 6 engine lubrication system 130
- Engine oil and oil filter 130
- Warning 130
- Engine lubrication system 7 7 131
- Engine oil and oil filter 131
- Warning 131
- 8 engine lubrication system 132
- Oil pressure relief valve 132
- Warning 132
- Engine lubrication system 7 9 133
- Oil pump 133
- Oil pump installation 133
- Oil pump removal 133
- 10 engine lubrication system 134
- Oil pipe 134
- Oil pipe installation 134
- Oil pipe removal 134
- Engine removal installation 135
- Engine removal installation 8 1 135
- Table of contents 135
- Engine removal installation 8 3 137
- Exploded view 137
- 4 engine removal installation 138
- Engine removal 138
- Engine removal installation 138
- Engine installation 139
- Engine removal installation 139
- Engine removal installation 8 5 139
- Crankshaft transmission 141
- Crankshaft transmission 9 1 141
- Table of contents 141
- Crankshaft transmission 9 3 143
- Exploded view 143
- Crankshaft transmission 9 5 145
- Exploded view 145
- 6 crankshaft transmission 146
- Specifications 146
- Crankshaft transmission 9 7 147
- Special tools and sealant 147
- 8 crankshaft transmission 148
- Crankcase 148
- Crankcase 149
- Crankshaft transmission 9 9 149
- Warning 149
- 10 crankshaft transmission 150
- Crankcase 150
- Crankshaft balancer shaft and connection rod 151
- Crankshaft transmission 9 11 151
- 12 crankshaft transmission 152
- Connecting rod big end seizure 152
- Crankshaft balancer shaft and connection rod 152
- Connecting rod big end radial clearance 153
- Connecting rod big end side clearance 153
- Crankshaft balancer shaft and connection rod 153
- Crankshaft transmission 9 13 153
- 14 crankshaft transmission 154
- Crankshaft balancer shaft and connection rod 154
- Crankshaft runout 154
- Connecting rod bend 155
- Connecting rod twist 155
- Crankshaft balancer shaft and connection rod 155
- Crankshaft transmission 9 15 155
- 16 crankshaft transmission 156
- Transmission 156
- Crankshaft transmission 9 17 157
- External shift mechanism inspection 157
- Reverse knob free play 157
- Reverse knob free play adjustment 157
- Reverse shift mechanism removal 157
- Transmission 157
- 18 crankshaft transmission 158
- Transmission 158
- Crankshaft transmission 9 19 159
- Transmission 159
- 20 crankshaft transmission 160
- Gear shift fork groove width 160
- Shift drum assembly 160
- Shift drum groove width 160
- Shift drum inspection 160
- Shift fork bending 160
- Shift fork ear thickness 160
- Shift fork guide pin diameter 160
- Shift fork wear 160
- Transmission 160
- Transmission gear inspection 160
- Crankshaft transmission 9 21 161
- Transmission 161
- 22 crankshaft transmission 162
- Transmission 162
- Ball bearing needle bearing and oil seal 163
- Crankshaft transmission 9 23 163
- Table of contents 165
- Wheels tires 165
- Wheels tires 10 1 165
- Exploded view 167
- Wheels tires 10 3 167
- 4 wheels tires 168
- Specifications 168
- Special tool and sealant 169
- Wheels tires 10 5 169
- 6 wheels tires 170
- Wheel alignment 170
- Caution 171
- Toe in inspection 171
- Toe in of front wheels 171
- Wheel alignment 171
- Wheels tires 10 7 171
- 8 wheels tires 172
- Wheel alignment 172
- Wheels rims 173
- Wheels tires 10 9 173
- 10 wheels tires 174
- Wheels rims 174
- Warning 175
- Wheels tires 10 11 175
- 12 wheels tires 176
- Maximum tire air pressure to seat beads when cold 176
- Tire air pressure when cold 176
- Warning 176
- Rear hub 177
- Wheels tires 10 13 177
- Final drive 179
- Final drive 11 1 179
- Table of contents 179
- Exploded view 181
- Final drive 11 3 181
- Exploded view 183
- Final drive 11 5 183
- 6 final drive 184
- Specifications 184
- Final drive 11 7 185
- Special tools and sealant 185
- 8 final drive 186
- Output bevel gear case 186
- Final drive 11 9 187
- Output bevel gear case 187
- 10 final drive 188
- Output bevel gear case 188
- Final drive 11 11 189
- Output bevel gear adjustment 189
- Output bevel gear case 189
- Output drive gear installation 189
- Output drive gear removal 189
- 12 final drive 190
- Backlash related parts 190
- Output bevel gear case 190
- Drive gear shims 191
- Driven bevel gear shims 191
- Final drive 11 13 191
- Output bevel gear case 191
- 14 final drive 192
- Bevel gear backlash front 192
- Output bevel gear case 192
- Bevel gear inspection 193
- Final drive 11 15 193
- Output bevel gear case 193
- 16 final drive 194
- Ball bearing inspection 194
- Cam damper inspection 194
- Oil seal inspection 194
- Output bevel gear case 194
- Final drive 11 17 195
- Propeller shaft 195
- Propeller shaft removal 195
- 18 final drive 196
- Propeller shaft 196
- Final drive 11 19 197
- Propeller shaft 197
- Propeller shaft joint and pinion gear joint inspection 197
- Propeller shaft joint boot inspection 197
- 20 final drive 198
- Rear axle 198
- Final drive 11 21 199
- Rear axle 199
- 22 final drive 200
- Axle shaft pipe assembly 200
- Rear axle 200
- Final drive 11 23 201
- Final gear case 201
- 24 final drive 202
- Final gear case 202
- Final drive 11 25 203
- Final gear case 203
- 26 final drive 204
- Bevel gear backlash rear 204
- Final gear case 204
- Pinion gear shims 204
- Ring gear shims 204
- Final drive 11 27 205
- Final gear case 205
- Final drive 11 29 207
- Final gear case 207
- Pinion gear assembly 207
- Pinion gear disassembly 207
- 30 final drive 208
- Ball bearing inspection 208
- Bevel gear inspection 208
- Caution 208
- Final gear case 208
- Oil seal inspection 208
- Brakes 209
- Brakes 12 1 209
- Table of contents 209
- Brakes 12 3 211
- Exploded view 211
- 4 brakes 212
- Specifications 212
- Brake adjustment 213
- Brake pedal free play inspection 213
- Brake pedal position adjustment 213
- Brake pedal position inspection 213
- Brakes 12 5 213
- Cam lever angle adjustment front and rear 213
- Front brake adjustment 213
- Rear parking brake lever and brake pedal free play adjustment 213
- Rear parking brake lever free play inspection 213
- 6 brakes 214
- Brake adjustment 214
- Cam lever angle front and rear 214
- Warning 214
- Brake drum and panel 215
- Brakes 12 7 215
- Front brake panel removal disassembly 215
- Warning 215
- 8 brakes 216
- Brake drum and panel 216
- Warning 216
- Brake drum and panel 217
- Brakes 12 9 217
- 10 brakes 218
- Brake drum and panel 218
- Rear brake panel removal disassembly 218
- Warning 218
- Brake drum and panel 219
- Brakes 12 11 219
- 12 brakes 220
- Brake drum and panel 220
- Brake drum wear 221
- Brake maintenance 221
- Brake shoe lining thickness front and rear 221
- Brake shoe lining wear 221
- Brakes 12 13 221
- Caution 221
- Front brake drum inside diameter 221
- Rear brake drum inside diameter 221
- 14 brakes 222
- Brake cam and cam hole wear 222
- Brake cam diameter 222
- Brake maintenance 222
- Brake shoe spring inspection 222
- Cam hole inside diameter 222
- Brake maintenance 223
- Brakes 12 15 223
- 16 brakes 224
- Brake cable installation 224
- Brake cable lubrication 224
- Brake cable removal 224
- Brake pedal and cables 224
- Brake pedal installation 224
- Suspension 225
- Suspension 13 1 225
- Table of contents 225
- Exploded view 227
- Suspension 13 3 227
- 4 suspension 228
- Shock absorbers 228
- Front suspension arm installation 229
- Front suspension arm removal 229
- Rear suspension arm removal 229
- Suspension 13 5 229
- Suspension arms 229
- 6 suspension 230
- Suspension arms 230
- Front suspension arm lubrication 231
- Suspension 13 7 231
- Suspension arm inspection 231
- Suspension arms 231
- Steering 233
- Steering 14 1 233
- Table of contents 233
- Exploded view 235
- Steering 14 3 235
- 4 steering 236
- Specifications 236
- Caution 237
- Steering 237
- Steering 14 5 237
- Steering stem removal 237
- 6 steering 238
- Caution 238
- Steering 238
- Steering knuckle removal 238
- Steering stem installation 238
- Steering 239
- Steering 14 7 239
- 8 steering 240
- Steering 240
- Tie rod end installation 240
- Tie rod length 240
- Steering 14 9 241
- Steering maintenance 241
- 10 steering 242
- Steering maintenance 242
- Handlebar 243
- Steering 14 11 243
- Frame 15 1 245
- Table of contents 245
- Exploded view 249
- Frame 15 5 249
- 6 frame 250
- Seat installation 250
- Seat removal 250
- Frame 15 7 251
- Front and rear fenders 251
- Front fender removal 251
- 8 frame 252
- Front and rear fenders 252
- Front fender installation 252
- Frame 15 9 253
- Front and rear fenders 253
- Rear fender removal 253
- 10 frame 254
- Front and rear fenders 254
- Rear fender installation 254
- Frame 15 11 255
- Front guard removal 255
- Rear guard removal 255
- Electrical system 257
- Electrical system 16 1 257
- Table of contents 257
- Electrical system 16 3 259
- Exploded view 259
- Electrical system 16 5 261
- Exploded view 261
- 6 electrical system 262
- Specifications 262
- Electrical system 16 7 263
- Special tools and sealant 263
- 8 electrical system 264
- Parts location 264
- Electrical system 16 9 265
- Precautions 265
- Electrical system 16 11 267
- Electrical wiring 267
- 12 electrical system 268
- Battery 268
- Battery 269
- Electrical system 16 13 269
- Warning 269
- 14 electrical system 270
- Battery 270
- Caution 270
- Ordinary charging 270
- Warning 270
- Battery 271
- Battery charging rate time table 271
- Battery test charging 271
- Battery troubleshooting guide 271
- Electrical system 16 15 271
- 16 electrical system 272
- Battery 272
- Alternator cover installation 273
- Alternator cover removal 273
- Charging system 273
- Electrical system 16 17 273
- 18 electrical system 274
- Alternator rotor removal 274
- Caution 274
- Charging system 274
- Alternator rotor installation 275
- Charging system 275
- Electrical system 16 19 275
- 20 electrical system 276
- Alternator stator installation 276
- Alternator stator removal 276
- Charging system 276
- Charging system 277
- Electrical system 16 21 277
- Regulator rectifier output voltage 277
- 22 electrical system 278
- Alternator output voltage 278
- Charging system 278
- Stator coil resistance 278
- Charging system 279
- Electrical system 16 23 279
- Rectifier circuit inspection 279
- 24 electrical system 280
- Caution 280
- Charging system 280
- Charging system 281
- Charging system circuit 281
- Electrical system 16 25 281
- 26 electrical system 282
- Caution 282
- Ignition coil removal 282
- Ignition system 282
- Spark plug cleaning inspection 282
- Spark plug gap inspection 282
- Spark plug removal installation 282
- Warning 282
- Electrical system 16 27 283
- Ignition coil arcing distance 283
- Ignition system 283
- Warning 283
- 28 electrical system 284
- Ignition coil primary peak voltage 284
- Ignition coil winding resistance 284
- Ignition system 284
- Warning 284
- Crankshaft sensor resistance 285
- Electrical system 16 29 285
- Ignition system 285
- 30 electrical system 286
- Connections 286
- Crankshaft sensor peak voltage 286
- Ignition system 286
- Electrical system 16 31 287
- Ignition system 287
- Ignition timing 287
- 32 electrical system 288
- Ignition system 288
- 34 electrical system 290
- Caution 290
- Electric starter system 290
- Starter motor installation 290
- Starter motor removal 290
- Electric starter system 291
- Electrical system 16 35 291
- Starter motor assembly 291
- Starter motor disassembly 291
- 36 electrical system 292
- Commutator cleaning inspection 292
- Electric starter system 292
- Commutator diameter 293
- Electric starter system 293
- Electrical system 16 37 293
- Starter motor brush length 293
- 38 electrical system 294
- Brush plate and terminal bolt inspection 294
- Electric starter system 294
- Starter circuit relay inspection 294
- Starter relay inspection 294
- Testing relay 294
- Electric starter circuit 295
- Electric starter system 295
- Electrical system 16 39 295
- Testing relay 295
- 40 electrical system 296
- Electric starter system 296
- Electrical system 16 41 297
- Starter motor clutch 297
- 42 electrical system 298
- Starter chain and sprockets 298
- Torque limiter inspection 298
- Electrical system 16 43 299
- Lighting system 299
- 44 electrical system 300
- Lighting system 300
- Electrical system 16 45 301
- Lighting system 301
- Lighting system circuit 301
- 46 electrical system 302
- Switches 302
- A main fuse removal 303
- Caution 303
- Electrical system 16 47 303
- Fuse inspection 303
- Appendix 307
- Appendix 17 1 307
- Table of contents 307
- 2 appendix 308
- Cable wire and hose routing 308
- Appendix 17 3 309
- Cable wire and hose routing 309
- 4 appendix 310
- Cable wire and hose routing 310
- Appendix 17 5 311
- Cable wire and hose routing 311
- 6 appendix 312
- Cable wire and hose routing 312
- Appendix 17 7 313
- Cable wire and hose routing 313
- 8 appendix 314
- Cable wire and hose routing 314
- Appendix 17 9 315
- Cable wire and hose routing 315
- 10 appendix 316
- Cable wire and hose routing 316
- Appendix 17 11 317
- Cable wire and hose routing 317
- 12 appendix 318
- Troubleshooting guide 318
- Appendix 17 13 319
- Troubleshooting guide 319
- 14 appendix 320
- Troubleshooting guide 320
- Appendix 17 15 321
- Troubleshooting guide 321
- Model application 322
- Part no 9924 1284 03 322
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